Sony KDL-55EX500 Service Manual
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Sony KDL-55EX500 Service Manual

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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE MANUAL

MODEL NAME
KDL-55EX500
KDL-55EX500
KDL-55EX501
KDL-60EX500
KDL-60EX500
ORIGINAL MANUAL ISSUE DATE: 1/2010
REVISION DATE
1/2010
9-883-843-51
REMOTE COMMANDER
RM-YD035
RM-YD035
RM-YD035
RM-YD035
RM-YD035
CONFIDENTIAL
ELECTRICAL SERVICE MANUAL
INTERNAL ONLY
SUBJECT
No revisions or updates are applicable at this time.
AZ1-K
DESTINATION
LEVEL
CONFIDENTIAL
US/CND
MX
US/CND
US/CND
MX
LCD DIGITAL COLOR TV
CHASSIS
3

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Summary of Contents for Sony KDL-55EX500

  • Page 1: Service Manual

    HISTORY INFORMATION FOR THE FOLLOWING MANUAL: AZ1-K SERVICE MANUAL CHASSIS MODEL NAME REMOTE COMMANDER DESTINATION LEVEL KDL-55EX500 CONFIDENTIAL RM-YD035 US/CND KDL-55EX500 RM-YD035 KDL-55EX501 RM-YD035 US/CND KDL-60EX500 RM-YD035 US/CND KDL-60EX500 RM-YD035 CONFIDENTIAL ELECTRICAL SERVICE MANUAL INTERNAL ONLY ORIGINAL MANUAL ISSUE DATE: 1/2010...

  • Page 2: Table Of Contents

    KDL-55EX500/55EX501/60EX500 TABLE OF CONTENTS SECTION TITLE PAGE Safety-Related Component Warning ..................................3 Safety Check-Out ........................................5 SECTION 1: DIAGRAMS ........................................6 1-1. Circuit Boards Location ...................................... 6 1-2. Printed Wiring Boards and Schematic Diagrams Information ..........................6 1-3. Block Diagrams ......................................... 8 1-4.

  • Page 3: Safety-Related Component Warning

    KDL-55EX500/55EX501/60EX500 SAFETY-RELATED COMPONENT WARNING There are critical components used in LCD color TVs that are important for safety. These components are identifi ed with shading and mark on the schematic diagrams and the electrical parts list. It is essential that these critical parts be replaced only with the part number specifi...
  • Page 4 Due to the higher melting point of Lead Free Solder the soldering iron tip temperature needs to be set to 370 degrees centigrade. This requires soldering equipment capable of accurate temperature control coupled with a good heat recovery characteristics. For more information on the use of Lead Free Solder, please refer to http://www.sony-training.com KDL-55EX500/55EX501/60EX500...

  • Page 5: Safety Check-Out

    KDL-55EX500/55EX501/60EX500 SAFETY CHECK-OUT The AC leakage from any exposed metal part to earth ground and After correcting the original service problem, perform the following from all exposed metal parts to any exposed metal part having a safety checks before releasing the set to the customer: return to chassis, must not exceed 0.5 mA (500 microamperes).

  • Page 6: Section 1: Diagrams

    KDL-55EX500/55EX501/60EX500 SECTION 1: DIAGRAMS 1-1. CIRCUIT BOARDS LOCATION D1 (KDL-55EX500/55EX501 ONLY) G5E (KDL-55EX500/55EX501 ONLY) G8S (KDL-60EX500 ONLY) SWITCH UNIT 1-2. PRINTED WIRING BOARDS AND SCHEMATIC DIAGRAMS INFORMATION All capacitors are in μF unless otherwise noted. pF : μμF 50WV or All voltages are in V.
  • Page 7 KDL-55EX500/55EX501/60EX500 REFERENCE INFORMATION Terminal name of semiconductors in silk screen RESISTOR CAPACITOR printed circuit ( : RN METAL FILM : TA TANTALUM Circuit Device Printed symbol Terminal name : RC SOLID : PS STYROL Collector Transistor : FPRD NONFLAMMABLE CARBON...

  • Page 8: Block Diagrams

    KDL-55EX500/55EX501/60EX500 1-3. BLOCK DIAGRAMS KDL-55EX500/55EX501/60EX500...

  • Page 9: Schematics And Supporting Information

    KDL-55EX500/55EX501/60EX500 1-4. SCHEMATICS AND SUPPORTING INFORMATION A BOARD SCHEMATIC DIAGRAM (1 OF 20) — — — — — — A 1/20 DC CONVERTER I 1-857-593-11 <AZ1K> A-P1 KDL-55EX500/55EX501/60EX500...

  • Page 10: A Board Schematic Diagram (2 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (2 OF 20) — — — — — — A 2/20 DC CONVERTER II 1-857-593-11 <AZ1K> A-P2 KDL-55EX500/55EX501/60EX500...

  • Page 11: A Board Schematic Diagram (3 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (3 OF 20) — — — — — — A 3/20 DC CONVERTER III 1-857-593-11 <AZ1K> A-P3 KDL-55EX500/55EX501/60EX500...

  • Page 12: A Board Schematic Diagram (4 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (4 OF 20) — — — — — — A 4/20 INPUT ANALOG VIDEO 1-857-593-11 <AZ1K> A-P4 KDL-55EX500/55EX501/60EX500...

  • Page 13: A Board Schematic Diagram (5 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (5 OF 20) — — — — — — A 5/20 INPUT D SUB 1-857-593-11 <AZ1K> A-P5 KDL-55EX500/55EX501/60EX500...

  • Page 14: A Board Schematic Diagram (6 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (6 OF 20) — — — — — — A 6/20 INPUT HDMI I 1-857-593-11 <AZ1K> A-P6 KDL-55EX500/55EX501/60EX500...

  • Page 15: A Board Schematic Diagram (7 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (7 OF 20) — — — — — — A 7/20 INPUT HDMI II 1-857-593-11 <AZ1K> A-P7 KDL-55EX500/55EX501/60EX500...

  • Page 16: A Board Schematic Diagram (8 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (8 OF 20) — — — — — — A 8/20 INPUT HDMI SW 1-857-593-11 <AZ1K> A-P8 KDL-55EX500/55EX501/60EX500...

  • Page 17: A Board Schematic Diagram (9 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (9 OF 20) — — — — — — A 9/20 TUNER 1-857-593-11 <AZ1K> A-P9 KDL-55EX500/55EX501/60EX500...

  • Page 18: A Board Schematic Diagram (10 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (10 OF 20) — — — — — — A 10/20 AUDIO IN 1-857-593-11 <AZ1K> A-P10 KDL-55EX500/55EX501/60EX500...

  • Page 19: A Board Schematic Diagram (11 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (11 OF 20) — — — — — — A 11/20 MT5388 INPUT 1-857-593-11 <AZ1K> A-P11 KDL-55EX500/55EX501/60EX500...

  • Page 20: A Board Schematic Diagram (12 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (12 OF 20) — — — — — — A 12/20 MT5388 DDR II 1-857-593-11 <AZ1K> A-P12 KDL-55EX500/55EX501/60EX500...

  • Page 21: A Board Schematic Diagram (13 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (13 OF 20) — — — — — — A 13/20 MT5388 LVDS 1-857-593-11 <AZ1K> A-P13 KDL-55EX500/55EX501/60EX500...

  • Page 22: A Board Schematic Diagram (14 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (14 OF 20) — — — — — — A 14/20 MT5388 PERIPHERAL/FLASH 1-857-593-11 <AZ1K> A-P14 KDL-55EX500/55EX501/60EX500...

  • Page 23: A Board Schematic Diagram (15 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (15 OF 20) — — — — — — A 15/20 MT5388 INPUT 1-857-593-11 <AZ1K> A-P15 KDL-55EX500/55EX501/60EX500...

  • Page 24: A Board Schematic Diagram (16 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (16 OF 20) — — — — — — A 16/20 AUDIO AMP 1-857-593-11 <AZ1K> A-P16 KDL-55EX500/55EX501/60EX500...

  • Page 25: A Board Schematic Diagram (17 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (17 OF 20) — — — — — — A 17/20 AUDIO SPDIF LINEOUT 1-857-593-11 <AZ1K> A-P17 KDL-55EX500/55EX501/60EX500...

  • Page 26: A Board Schematic Diagram (18 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (18 OF 20) — — — — — — A 18/20 IR/USB/KEYPAD 1-857-593-11 <AZ1K> A-P18 KDL-55EX500/55EX501/60EX500...

  • Page 27: A Board Schematic Diagram (19 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (19 OF 20) — — — — — — A 19/20 MCU I 1-857-593-11 <AZ1K> A-P19 KDL-55EX500/55EX501/60EX500...

  • Page 28: A Board Schematic Diagram (20 Of 20)

    KDL-55EX500/55EX501/60EX500 A BOARD SCHEMATIC DIAGRAM (20 OF 20) — — — — — — A 20/20 MCU II 1-857-593-11 <AZ1K> A-P20 KDL-55EX500/55EX501/60EX500...
  • Page 29 KDL-55EX500/55EX501/60EX500 [DC CONVERTER I, DC CONVERTER II, DC CONVERTER II, INPUT ANALOG VIDEO, INPUT D SUB, INPUT HDMI I, INPUT HDMI II, INPUT HDMI SW, TUNER, AUDIO IN, MT5388 INPUT, MT5388 DDR II, MT5388 LVDS OUT, MT5388 PERIPHERAL/FLASH, MT5388 POWER, AUDIO AMP, AUDIO SPDIF LINEOUT, IR/USB/KEYPAD, MCU I, MCU II] COMPONENT SIDE —...
  • Page 30 KDL-55EX500/55EX501/60EX500 [DC CONVERTER I, DC CONVERTER II, DC CONVERTER II, INPUT ANALOG VIDEO, INPUT D SUB, INPUT HDMI I, INPUT HDMI II, INPUT HDMI SW, TUNER, AUDIO IN, MT5388 INPUT, MT5388 DDR II, MT5388 LVDS OUT, MT5388 PERIPHERAL/FLASH, MT5388 POWER, AUDIO AMP, AUDIO SPDIF LINEOUT, IR/USB/KEYPAD, MCU I, MCU II]...

  • Page 31: D1 Board Schematic Diagram

    KDL-55EX500/55EX501/60EX500 D1 BOARD SCHEMATIC DIAGRAM JL6626 JL6627 JL6636 JL6648 JL6645 FROM PFC OUT(DC395V) L6601 R6600 — 0 . 4 7 68uH 1/2W JL6601 CN6600 JL6623 EY6600 R6601 PFC_OUT(395V) C6602 1/4W JS6601 PRI_GND 450V FPRD JL6603 JL6609 JL6611 JL6628 JL6650 JL6643...
  • Page 32 KDL-55EX500/55EX501/60EX500 [INVERTER] COMPONENT SIDE D P S - 7 4 ( C H ) — 1 - 8 8 1 - 5 2 0 - 2 1 J S 6 7 0 7 ( 1 7 3 1 5 9 8 2 1 )
  • Page 33 KDL-55EX500/55EX501/60EX500 [INVERTER] CONDUCTOR SIDE J R 6 7 1 3 E T 6 7 0 3 — J R 6 7 1 5 J L 6 7 9 6 J L 6 7 9 5 1 - 8 8 1 - 5 2 0 - 2 1...

  • Page 34: G5E Board Schematic Diagram

    KDL-55EX500/55EX501/60EX500 G5E BOARD SCHEMATIC DIAGRAM — — — — — — — — — — — — — — POWER — 1-474-203-11 <AZ1L> G5E-P1 KDL-55EX500/55EX501/60EX500...
  • Page 35 KDL-55EX500/55EX501/60EX500 [POWER] [POWER] COMPONENT SIDE CONDUCTOR SIDE — — — — — — — — — — — — — — — — — — — — — — — — KDL-55EX500/55EX501/60EX500...

  • Page 36: G8S Board Schematic Diagram

    KDL-55EX500/55EX501/60EX500 G8S BOARD SCHEMATIC DIAGRAM — — — — — — — — — — — — — POWER — — 1-474-205-11 <AZ1K> G8S-P1 KDL-55EX500/55EX501/60EX500...
  • Page 37 KDL-55EX500/55EX501/60EX500 [POWER] [POWER] COMPONENT SIDE CONDUCTOR SIDE — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — KDL-55EX500/55EX501/60EX500...

  • Page 38: Hrk Board Schematic Diagram

    KDL-55EX500/55EX501/60EX500 HRK BOARD SCHEMATIC DIAGRAM — — — — — — — IR/LED — — KDL-55EX500/55EX501/60EX500...
  • Page 39 KDL-55EX500/55EX501/60EX500 [IR/LED] [IR/LED] COMPONENT SIDE CONDUCTOR SIDE 1 - 8 8 1 - 7 5 3 - 1 1 B C D ( 1 7 3 1 6 8 4 1 1 ) 1 2 3 4 > E P G W G N <...

  • Page 40: Section 2: Electrical Parts List

    KDL-55EX500/55EX501/60EX500 SECTION 2: ELECTRICAL PARTS LIST Items marked with an asterisk are not stocked since they NOTE: The components identifi ed by shading RESISTORS are seldom required for routine service. Expect some delay mark are critical for safety. Replace only •...
  • Page 41 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C516 1-100-916-11 CERAMIC CHIP 0.1μF C292 1-104-653-11 ELECT 220μF C517 1-100-916-11 CERAMIC CHIP 0.1μF C293 1-116-079-11 CERAMIC CHIP 10μF C518 1-114-332-11 CERAMIC CHIP 22μF 6.3V C294 1-100-916-11 CERAMIC CHIP 0.1μF...
  • Page 42 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C713 1-100-916-11 CERAMIC CHIP 0.1μF C4303 1-164-849-11 CERAMIC CHIP 0.50pF 50V C714 1-162-925-11 CERAMIC CHIP 68pF C4304 1-100-905-11 CERAMIC CHIP 0.001μF 10% C715 1-164-845-11 CERAMIC CHIP 0.25pF 50V...
  • Page 43 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C4486 1-114-219-21 CERAMIC CHIP 1μF C6009 1-114-868-11 CERAMIC CHIP 0.1μF C4487 1-114-219-21 CERAMIC CHIP 1μF C6010 1-164-854-11 CERAMIC CHIP 15pF C4488 1-100-916-11 CERAMIC CHIP 0.1μF C6011 1-116-470-11 CERAMIC CHIP 0.01μF...
  • Page 44 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES C8307 1-100-916-11 CERAMIC CHIP 0.1μF C6606 1-100-916-11 CERAMIC CHIP 0.1μF C8308 1-100-916-11 CERAMIC CHIP 0.1μF C6607 1-100-916-11 CERAMIC CHIP 0.1μF C8309 1-162-926-11 CERAMIC CHIP 82pF C6608 1-114-219-21 CERAMIC CHIP 1μF...
  • Page 45 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES DIODE IC305 6-715-063-01 M24C32-WMN6TP IC308 6-706-498-01 TC7SH08F(T5RSONYJF) D232 6-503-079-01 DIODE BAS16H IC502 6-715-044-01 H5PS5162FFR-20LR D234 6-500-400-01 DIODE BAV99-215 IC503 6-715-044-01 H5PS5162FFR-20LR D805 6-500-400-01 DIODE BAV99-215 IC901 6-715-059-01...
  • Page 46 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES L6154 1-500-960-11 FERRITE 0μH L406 1-500-964-11 FERRITE 0μH L6155 1-500-960-11 FERRITE 0μH L407 1-500-964-11 FERRITE 0μH L408 1-500-964-11 FERRITE 0μH L6156 1-500-960-11 FERRITE 0μH L409 1-500-964-11 FERRITE 0μH...
  • Page 47 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES Q8158 6-551-696-01 TRANSISTOR ISA1235AC1TP-1EF R262 1-218-977-11 METAL CHIP 100K 1/16W Q8160 6-551-696-01 TRANSISTOR ISA1235AC1TP-1EF R263 1-218-965-11 METAL CHIP 1/16W Q8301 6-551-940-01 TRANSISTOR DTC623TKT146 R265 1-218-961-11 METAL CHIP 4.7K...
  • Page 48 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R376 1-218-937-11 METAL CHIP 1/16W R906 1-218-941-81 METAL CHIP 1/16W R377 1-218-937-11 METAL CHIP 1/16W R907 1-218-965-11 METAL CHIP 1/16W R378 1-218-937-11 METAL CHIP 1/16W R908 1-208-675-11 METAL CHIP 0.50% 1/16W...
  • Page 49 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R4203 1-218-990-81 SHORT CHIP R4361 1-218-990-81 SHORT CHIP R4210 1-218-990-81 SHORT CHIP R4451 1-218-961-11 METAL CHIP 4.7K 1/16W R4211 1-218-990-81 SHORT CHIP R6001 1-218-941-11 METAL CHIP 1/16W...
  • Page 50 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES R6166 1-208-755-11 METAL CHIP 0.50% 1/10W R8171 1-216-801-11 METAL CHIP 1/10W R6168 1-218-961-11 METAL CHIP 4.7K 1/16W R8174 1-248-492-11 RES-CHIP 1/3W R6170 1-218-937-11 METAL CHIP 1/16W R8175...
  • Page 51 KDL-55EX500/55EX501/60EX500 REF. NO. PART NO. DESCRIPTION VALUES REF. NO. PART NO. DESCRIPTION VALUES RN508 1-234-714-11 RES, NETWORK 56 (1005X4) RN509 1-234-714-11 RES, NETWORK 56 (1005X4) RN510 1-234-714-11 RES, NETWORK 56 (1005X4) A-1758-163-A HRK BOARD, MOUNTED RN8151 1-234-372-11 RES, NETWORK 100...

  • Page 52: Appendix A: Encryption Key Components

    MUST BE RETURNED to Sony. b) and if the core charge is NOT covered under the product warranty, the defective un-repaired or modifi...

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